Conveyor belt assembly

ABSTRACT

A conveyor assembly includes a support structure for a belt constructed of interlocking segments. The support structure includes straight segments that may be cut to any desired length. These straight segments are joined using a friction-fit connector. The connector does not require any drilling or other modifications to the straight segments. The straight segments may be constructed from a single sheet of stainless steel. The conveyor assembly may also include support arms, legs and other accessories.

CLAIM OF PRIORITY

This application is a continuation of U.S. application Ser. No.10/606,321, filed on Jun. 25, 2003, now U.S. Pat. No. 7,137,506 which isa continuation-in-part of U.S. application Ser. No. 09/695,344 filed onOct. 24, 2000, now U.S. Pat. No. 6,612,426.

FIELD OF THE INVENTION

The present invention relates generally to a conveyor belt assembly andmore specifically to a conveyor belt support structure used inconjunction with a conveyor belt having a plurality of interlockingsegments.

DESCRIPTION OF RELATED ART

Conveyor belts are commonly used to move products through amanufacturing facility. They can be used to move a wide range ofproducts such as machined parts, electronics, foods and pharmaceuticals.

One common conveyor assembly uses interlocking plastic sections to forma conveyor belt. Each plastic section is hingedly attached to twoadjacent plastic sections along parallel axes. Together, theseinterlocked plastic sections form a continuous loop that is used as aconvey belt. One typical manufacturer of this type of convey belt andassociated assembly is FlexLink. Their products are shown and describedin The FlexLink Catalog, copyright 1998, and Conveyor Systems andAutomation Components Product Overview, copyright 1998. Both of thesedocuments are available from FlexLink, and are incorporated herein byreference. FlexLink may be contacted in the U.S. at FlexLink SystemsInc., 1530 Valley Center Parkway, Suite 200, Bethlehem, Pa. 18017,telephone 1-800-782-1399, or in Sweden at FlexLink Systems AB, Norden,SE-415 50 Göteborg, telephone 1-46-(0)31-337 31 00, or on the Internetat http://www.flexlink.com.

A conveyor assembly made by FlexLink will include a plastic conveyorbelt, at least one conveyor beam, an idler end unit and an end driveunit. In addition, the conveyor assembly may include one or morevertical or horizontal bends, guide rails and other related components.

The conveyor beams manufactured by FlexLink are constructed of extrudedaluminum. These conveyor beams offer a number of advantages. Forexample, they are inexpensive to manufacture at virtually any length.For shipping, the aluminum conveyor beams may be cut at fixed lengths.Then, to construct a longer conveyor belt assembly, a number of thefixed length conveyor beams are easily jointed using conveyor beamconnectors. The lightweight aluminum provides for easy construction andresists corrosion in most manufacturing environments.

The extruded aluminum conveyor beams, however, also suffer from a numberof limitations. For example, in some manufacturing environments, thealuminum conveyor beams suffer from corrosion damage. In addition, somemanufacturing facilities must be kept extremely clean. One example ofthis type of plant is a pharmaceutical or food plant. In theseenvironments, cleanliness is of absolute importance. While extrudedaluminum conveyor beams are commonly used in this environment, theirconstruction tends to collect dirt and dust along interior and exteriorsurfaces that are difficult to clean.

Moreover, in pharmaceutical plants, careful inventory must be maintainedof the product. If a conveyor belt is in any way disturbed so thatpills, capsules or other products are spilled, industry protocolrequires every effort to account for any lost product. Due to itsconstruction, extruded aluminum conveyor beams typically include aninterior surface that is difficult to see without dissembling theconveyor belt. As a result, when such a conveyor assembly suffers adisturbance that causes a spill, the lost product may be difficult torecover.

A number of prior art sanitary conveyor systems address these problems.These sanitary conveyor systems may be constructed of stainless steel,or other metals and materials. These sanitary conveyor systems, however,typically require difficult assembly such as drilling or welding at theinstallation site. Moreover, these sanitary conveyor systems typicallyoffer only limited configuration options without incurring extensivemodification work.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a conveyor belt systemincludes at least a pair of beams, a connector and a conveyor belt. Thebeams are formed by bending a single sheet of metal to define a firstinterior channel. The connector has a body formed by bending a singlesheet of metal to define a horizontal face and a pair of side walls. Aportion of the connector is positioned within each beam to form afriction fit. The conveyor belt has a plurality of interlocking plasticsegments and an upper portion extending above the first and second beamand a lower portion extending below the first and second beam.

According to a further aspect of the invention, the connector includes apair of rods extending from end to end of the body. The pair of rodshelp to form the friction fit with the beams.

According to another aspect of the invention, a conveyor housingespecially suited for supporting a conveyor belt having a plurality ofinterlocking plastic segments includes conveyor beams, connectors, armpairs and associated members. The conveyor beams have an inclined rightside wall connected to an inclined left side wall and an interiorchannel defined therebetween. The connector is positioned within theinterior channel of adjoining beams. The arm pairs are spaced along theconveyor beams to support an upper portion of the conveyor belt.Finally, the associated members press the arms against the conveyorbeams to form a friction fit.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of one preferred conveyor belt assembly100 including conveyor beams 102, support arms 104, idler end 106, wheelbend 108, end drive 110, plastic belt 112 and supports 114.

FIG. 1B is a cross-sectional view of conveyor belt assembly 100 takenalong 1B-1B of FIG. 1A.

FIG. 2A is a perspective view of the conveyor beam 102 of FIG. 1A.

FIG. 2B is an elevation view of conveyor beam 102 of FIG. 1A.

FIG. 3A is a perspective view of connector 116 of FIG. 1B.

FIG. 3B is an elevation view of connector 116 of FIG. 1B.

FIG. 4A is an elevation view of support arm 104 of FIG. 1A showing anoutside view.

FIG. 4B is an elevation view of support arm 104 of FIG. 1A showing aright side view.

FIG. 4C is an elevation view of support arm 104 of FIG. 1A showing aninside view.

FIG. 4D is an elevation view of support arm 104 of FIG. 1A showing aleft side view.

FIG. 5A is an elevation view of idler end 106 of FIG. 1A.

FIG. 5B is a cross-sectional view of idler end 106 taken along 5B-5B ofFIG. 5A.

FIG. 5C is a cross-sectional view of idler end 106 taken along 5C-5C ofFIG. 5A.

FIG. 6A is a plan view of wheel bend 108 of FIG. 1A.

FIG. 6B is a partial cross-sectional view of wheel bend 108 taken along6B-6B of FIG. 6A.

FIG. 7A is an elevation view of end drive 110 of FIG. 1A.

FIG. 7B is a cross-sectional view of end drive 110 taken along 7B-7B ofFIG. 7A.

FIG. 7C is a cross-sectional view of end drive 110 taken along 7C-7C ofFIG. 7A.

FIG. 8 is an elevation view of another preferred conveyor beam 802 andconnector 804.

FIG. 9 is a perspective view of another preferred conveyor beam 900.

FIG. 10 is an elevation view of one preferred guide support 1000 thatincludes a vertical arm 1008, a base 1010, a body 1012 and a support arm1014.

FIG. 11 is an elevation view of another preferred guide support 1100that includes a base 1110, a body 1112 and a support arm 1114.

FIG. 12 is an elevation view of bolt 1122 of FIG. 11.

FIG. 13A is an elevation view of a portion of a leg attachment mechanism1300 shown from an end view.

FIG. 13B is an elevation view of a portion of the leg attachmentmechanism 1300 shown from a side view.

FIG. 14 is an elevation view of side-by-side connector 1400.

FIG. 15A is a plan view of an attachment block 1500 having sides 1510and 1520.

FIG. 15B is an elevation view of side 1510 of attachment block 1500.

FIG. 15C is an elevation view of side 1520 of attachment block 1500.

FIG. 16A is a plan view of connector 1600 having end 1602 and side 1604.

FIG. 16B is an elevation view of end 1602 of connector 1600.

FIG. 16C is an elevation view of side 1604 of connector 1600.

FIG. 17 is an end view of connectors 1600 inside a beam.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

One preferred embodiment of the present invention is shown in FIG. 1A.This conveyor assembly 100 includes conveyor beams 102, support arms104, idler end 106, wheel bend 108, end drive 110, belt 112 and supports114. Conveyor assembly 100 is configured to move products along astraight path from idler end 106 to wheel bend 108. At wheel bend 108,the products experience a ninety-degree turn and are then moved along astraight path toward end drive 110. The speed of this path may becontrolled depending upon the needs of the particular application. In aproduction-line application, the product would be received from aprocessing step at idler end 106 and would be passed to anotherprocessing step at end drive 110. In addition, processing steps may beperformed along the conveyor assembly 100.

Belt 112 is constructed of a plurality of interlocking plastic segmentssuch as are commercially available from FlexLink, whose contactinformation may be found above, or Rexnord Corporation, TabletopOperation , 738 10th Avenue, PO BOX 43, Grafton, Wis. 53024, telephone(414) 375-5160, or Intralox Inc., 201 Laitram Lane, PO Box 50699Harahan, La. 70123, telephone (504) 733-0463. These interlocking plasticsegments are pivotally attached to one another so that the upper portionof belt 112 make a one-hundred-and-eighty-degree turn at idler end 106and end drive 110. Different models of interlocking plastic segmentsallow for different turn radii. Acceptable turn radii information may beobtained from the manufacturer. In addition, the interlocking plasticsegments also can flex along the horizontal plane defined by the uppersurface of the conveyor. This flex allows belt 112 to turn around wheelbend 108. Acceptable turn radii information for this flex may also beobtained from the manufacturer. Along the lower surface of the upperportion of belt 112, a pair of vertical blades (or more generally bars)support the interlocking plastic segments. These blades run along thelength of conveyor beams 102 and connect to conveyor beams 102 bysupport arms 104. The lower portion of belt 112 is also supported bywheel bend 108.

End drive 110 includes a motor that drives a gear (not shown). The teethof the gear engage the interlocking plastic segments so that when themotor is powered, the gear draws the upper plastic segments toward enddrive 110. This effectuates movement along the upper surface from idlerend 106 to wheel bend 108 and then to end drive 110.

The conveyor assembly rests upon supports 114. These connect to conveyorbeams 102 by a friction fit mechanism that is described further belowwith reference to FIGS. 13A and 13B.

In this preferred embodiment, conveyor belt assembly 100 uses twostraight conveyor beams 102 along the first segment from the idler end106 to the wheel bend 108. A connector that will be further describedbelow joins these two conveyor beams 102. Depending upon the particularapplication requirements, additional conveyor beams 102 may be added toextend the reach of this first segment. Likewise, the single conveyorbeam 102 that has been used along the second straight segment from wheelbend 108 to end drive 110 may be extended by insertion of addition ofconveyor beams 102.

Wheel bend 108 connects the first straight segment to the secondstraight segment at an approximately ninety-degree angle. Other wheelbends may be used to provide virtually any horizontal or vertical angleand other combinations of wheel bends and straight sections may be usedto move products along almost any path.

Turning to FIG. 1B, the conveyor assembly 100 will be further described.As shown, belt 112 includes an upper portion 112A and a lower portion112B. The upper portion of belt 112A is supported from conveyor beam 102by support arms 104A and 104B, by support blades 126A and 126B and byplastic caps 128A and 128B. More specifically, a lower end 105A and 105Bof support arms 104A and 104B, respectively, rest upon conveyor beam102. Lower ends 105A and 105B each define a horizontal surface thatrests upon the upper surface of conveyor beam 102. In addition, lowerends 105A and 105B each extend along the side of conveyor beam 102. Thecontours of this extension follow the side of conveyor beam 102 so thatit forms a tight fit against the side of conveyor beam 102. In otherwords, the profile of lower ends 105A and 105B match the profile of therespective side of conveyor beam 102.

Approximately midway up support arms 104A and 104B, coupling nut 122passes through a hole defined by an interior surface of the support arms104A and 104B. On the left side, the body of bolt 124A is also passedthrough an exterior surface of support arm 104A and its threaded endengages the left end of coupling nut 122. The bolt head 138A and anassociated washer 140A press against the exterior surface of support arm104A. Likewise, on the right side, the body of bolt 124B is passedthrough an exterior surface of support arm 104B and its threaded endengages the right end of coupling nut 122. The bolt head 138B and anassociated washer 140B press against the exterior surface of support arm104B. As bolts 124A and 124B are turned into coupling nut 122, they drawthe support arms 104A and 104B together. The lower ends 105A and 105Bpress against conveyor beam 102, and the upper end presses against pin120.

Pin 120 extends through the interior surface of support arms 104A and104B to press against the exterior surface of each support arm. Thisconfiguration rigidly attaches the support arms 104A and 104B to theconveyor beam 102 without requiring additional support. Morespecifically, this configuration does not require holes in conveyor beam102 for bolts, screws, rivets or any other attachment device, nor doesit require welds or any other attachment means. As a result, theconveyor beams 102 may be cut to any desired length without requiringany further manufacturing process for attaching the support arms. Thesupport arms 104A and 104B may be added anywhere along the length of theconveyor beams 102.

Support blades 126A and 126B rest within a slot in support arms 104A and104B, respectively. To hold the support blade 126A firmly in place, abolt 127 passes through a threaded hole in support arm 104A. The bolt isturned against support blade 126A to hold support blade 126A firmly inplace.

The lower portion of belt 112B is supported by a slot defined by thelower surface of conveyor beam 102, and protected using plastic caps130A and 130B. More specifically, each plastic segment of conveyor belt112 includes a body 132, a conveyor surface 134 and a pair of lugs 136Aand 136B situated on opposite sides of the body 132. Body 132 fitswithin the slot defined by the lower surface of conveyor beam 102, whilelugs 136A and 136B extend beyond the slot on the top side and conveyorsurface 134 extends beyond the slot on the bottom side. As a result, theplastic segments of belt 112 are prevented, within certain tolerances,from moving laterally between plastic cap 130A and 130B and from movingvertically, within certain tolerances, by plastic caps 130A and 130B,which are situated between conveyor surface 134 and lugs 136. However,the lower portion of belt 112B is free to move longitudinally within theslot defined by the lower surfaces of conveyor beam 102. In operation,the upper portion of belt 112A moves along plastic caps 128 in a firstdirection while the lower portion of belt 112B moves along plastic caps130 in the opposite direction.

In an alternative embodiment, the lower portion of belt 112B may runinside the conveyor beam and rest on top of the lower face of theconveyor beam. In this configuration, the conveyor beam must be at leastas wide as the conveyor belt 112. Specifically, turning to FIG. 1B, theinterior of the connector must be at least as wide as the conveyor belt112.

Returning to the embodiment shown in FIG. 1, The friction betweenplastic caps 128 or 130 and the plastic belt 112 is less than thefriction between the stainless steel support blades 126 and the plasticbelt 112. Accordingly, plastic caps 128 and 130 are used to minimizewear on belt 112.

Returning to the upper portion of belt 112A, since the lugs of therespective plastic segments are not engaged by a slot, the upper portionmay be lifted off of the support blades 126A and 126B. For a conveyorbelt fixed along a support assembly, the belt tension will determine howfar off the belt may be lifted from the support blades 126A and 126B Asmentioned above, additional conveyor beams 102 may be added to increasethe length of a conveyor segment. Additional beams are attached using aconnector 116 and screws 118. Screws include an allen-keyed head and athreaded body. Of course, those skilled in the art will appreciate thatother screw heads may be used. The connector 116 fits within theconveyor beam 102. As screws 118 are turned through connector 116 theybegin to press against conveyor beam 102 and force connector 116 topress against conveyor beam 102 as well. This high-friction fit acts tosecure one end of connector 116 within conveyor beam. To add anotherconveyor beam, the other end of connector 116 is simply placed withinthe additional conveyor beam and screws are again used to provide ahigh-friction fit.

This particular configuration avoids the use of bolts, screws, rivets,welds or other attachment means that would require structuralmodification to a conveyor beam. As a result, the conveyor beams may becut to any desired length and connected using this simple mechanism.This provides an efficient means for installing a new conveyor beltsystem in a manufacturing plant.

Turning to FIGS. 2A and 2B, one preferred conveyor beam will bedescribed in further detail. Conveyor beam 102, also of FIG. 1A, ispreferably constructed from a single sheet of stainless steel or anyother malleable metal. The single sheet of stainless steel isrectangular having a base of significantly greater dimension than itsheight. This single sheet of stainless steel is bent to form conveyorbeam 102, and the elongated base of the rectangular sheet extends alongthe length of the conveyor beam 102. Of course, those skilled in the artwill appreciate that the conveyor beam may be constructed using othermanufacturing methods.

More specifically, conveyor beam 102 includes an upper face 210 thatdefines a substantially horizontal plane. The upper face is rectangularin shape. The side of the rectangle that extends along the length of theconveyor beam 102 is significantly longer than the other side of therectangle.

Side wall 220 connects to upper face 210 along one of its long sides.Side wall 222 connects to upper face 210 along the opposite side. Bothsidewalls 220 and 222 extend along the length of the conveyor beam 102.Side walls 220 and 222 are both bent inward so that each defines aconcave surface. The lower end of side walls 220 and 222 connect to alower face 212. As with the upper face 210, lower face defines asubstantially horizontal plane parallel to that of the upper face 210.In addition, lower face 212 defines a slot 214 that is used to engageand support the interlocking plastic segments of the conveyor beltassembly 100.

Turning to FIG. 2B, the contours of conveyor beam 102 will be furtherdescribed. Side wall 220 (shown in FIG. 2A) includes an upper inclinedwall 242 and a lower inclined wall 244. Upper inclined wall 242 connectswith upper face 210 along bend 234. The interior angle defined by bend234 is less than ninety-degrees (acute). Likewise side wall 222 (shownin FIG. 2A) includes an upper inclined wall 246 and a lower inclinedwall 248. Upper inclined wall 246 connects with upper face 210 alongbend 236. The interior angle defined by bend 236 is less thanninety-degrees. As the screws or bolts (or more generically, threadedrods) are turned through connector 116 to press against upper face 210,connector 116 presses against lower face 212. This provides a rigid,high-friction fit between the conveyor beam 102 and connector 116.

Upper inclined wall 242 connects to lower inclined wall 244 along bend232. The exterior angle defined by bend 232 is greater than ninetydegrees (obtuse). Likewise, upper inclined wall 246 connects to lowerinclined wall 248 along bend 238. The exterior angle defined by bend 238is greater than ninety degrees.

Lower inclined wall 244 connects to a left portion of lower face 212Aalong bend 230. The interior angle defined by bend 230 is less thanninety degrees and the left portion of lower face 212A is substantiallyparallel to upper face 210. Likewise, lower inclined wall 248 connectsto a right portion of lower face 212B along bend 240. The interior angledefined by bend 240 is less than ninety degrees and the right portion oflower face 212B is substantially parallel to upper face 210.

Again, the slot defined between the lower face 212A and lower face 212Bis used to engage and support plastic segments of a conveyor belt. Thespace between lower inclined wall 244 and lower inclined wall 248 housesthe lugs 136 of the plastic segments (shown in FIG. 1B).

Again, conveyor beam 102 is preferably constructed of a single sheet ofstainless steel. Each of bends 230-240 are made in this single sheet ofstainless steel. When used in conjunction with conveyor belt assembly100, conveyor beam 102 does not require any further construction.Specifically, conveyor beam 102 does not require any holes or othermodifications for attachment with the other parts of the conveyor beltassembly 100. As a result, the conveyor beam 102 may be cut on locationto any desired length and easily assembled with no drilling or weldingrequired.

Turning to FIGS. 3A and 3B, one preferred connector will be described infurther detail. Connector 116 includes an upper face 310, a side wall312 and a side wall 314. Upper face 310 is substantially rectangular andconnects to side wall 312 along bend 320. Upper face 310 connects toside wall 314 along bend 322 which is on the opposite side of bend 320.Bends 320 and 322 each define an interior angle of approximately ninetydegrees. The bottom surface of side walls 312 and 314 engage a leftportion of lower face 212A and a right portion of lower face 212B,respectively.

A first end of connector 116A defines four threaded holes 316. These areused to receive threaded rods that engage the conveyor beam. Thethreaded rods are turned through upper surface 310 so that the threadedrods will contact the upper face 210 of conveyor beam 102. As describedabove, this forms a rigid friction-fit with that conveyor beam. A secondend of connector 116B also defines four threaded holes 318. These arealso used to receive threaded rods that engage the second conveyor beam.This forms a rigid friction-fit with the second conveyor beam andoperates to joint the two conveyor beams together. By combining suchconveyor beam segments, virtually any length can be provided.

Alternatively, in another preferred embodiment, the threaded holes arepositioned along the corners of connector 116 so that the threaded rodsthat pass therethrough press against bends 234 and 236. The threadedholes may placed at other locations provided the threaded holes arepositioned so that when the threaded rods are turned therethrough, theconnector forms a friction fit with the conveyor beam.

Preferably, the connector is constructed from a single sheet ofstainless steel of the same composition as conveyor beams 102. Ofcourse, those skilled in the art will appreciate that the connector canbe made using other material and/or construction techniques. Likewise,the conveyor beams and other components can be made using othermaterials and/or construction techniques.

Turning to FIGS. 4A-4D, one preferred support arm will be described infurther detail. Support arm 104 includes blade guides 410 and 412, whichare arranged along its top portion. Blade guides 410 and 412 define avertical slot 414 this is approximately the same width as, or justslightly wider than support blade 126 (shown in FIG. 1B). Blade guides410 and 412 are connected along their bottom by blade rest 413. Thisprovides a lower bounds for slot 414. As part of conveyor belt assembly100, slot 414 holds support blade 126 in a substantially verticalorientation.

Support arm 104 also includes an exterior face 416, a left face 418, aninterior face 420 and a right face 422. The interior face 420 defines athreaded hole 432. A bolt is turned through hole 432 to secure supportblade 126 in place (shown in FIG. 1B). More specifically, the end of thebolt presses against the interior side of support blade 126 and forcesthe exterior side of support blade 126 against blade guide 410. Thisprovides a rigid, high-friction fit that prevents any movement of thesupport blade 126.

A top portion of left face 418 and a top portion of right face 422connect to the bottom portion of blade guides 410 and 412. The bottomportion of left face 418 and the bottom portion of right face 422 eachinclude a beam contour 424. Beam contour 424 is shaped to match theprofile of the conveyor beam 102. Beam contour 424 includes a horizontalportion 426 that rests upon the top of conveyor beam 102. Beam contour424 also includes an inclined portion 428 that matches the slope of theupper inclined wall of the conveyor beam 102. When support arm 104engages conveyor beam 102, inclined portion 428 prevents the support arm104 from moving in a vertical direction. When used in combination withanother arm, this provides a rigid friction fit with a conveyor beam.

Approximately midway along support arm 104, exterior face 416 defines abolt hole 430. Interior face 420 also defines a bolt hole 436 at thesame level, and a pin hole 434 positioned above bolt hole 436. As partof conveyor assembly 100, a bolt is passed through bolt holes 430 and436 to engage a coupling nut. A pin is passed through pin hole 434 andpresses against exterior face 416. Returning to FIG. 1B, turning bolt124A or 124B into coupling nut 122 draws support arms 104A and 104Btogether. As the bolts 124A and 124B are further tightened, they act aspart of a tension member connecting support arms 104A and 104B. Inopposition, pin 120 presses against the exterior of support arms 104Aand 104B to keep the arms a fixed distance apart. In this regard, as thebolts 124A and 124B are tightened, pin 120 acts as a compression member.

The lower exterior face of support arm 104 defines a substantiallyhorizontal groove 440. The lower end of any auxiliary attachmentprovides a lip to engage the horizontal groove 440. This groove 440secures the base of any auxiliary attachment in a perpendicular positionwhile using only one bolt to attach the base. Moreover, this attachmentmechanism does not require any further drilling or any othermanufacturing process.

Preferably, support arms 104 are constructed of stainless steel of thesame composition as conveyor beams 102.

Turning to FIGS. 5A-5C, one preferred idler end will be described infurther detail. FIG. 5A shows the idler end without a conveyor belt.FIG. 5B shows the idler end with a conveyor belt. FIG. 5C shows theidler end with an upper portion of the conveyor belt. Idler end 106(shown in FIG. 5A) includes a side wall 512 and a side wall 514. Thedistance between the interior surface of these walls is approximatelyequal to the width of the conveyor surface. Side walls 512 and 514 areconnected by connector 502, bolts 510, axle 511, bolts 520, and couplingnut 521. Connector 502 extends beyond side walls 512 and 514 andprovides an end with approximately the same shape as one end ofconnector 116. Accordingly, connector 502 is used to provide a rigid,high friction fit with a conveyor beam 102.

As a lower surface of a conveyor belt is received by idler end 106, thelower surface is supported and guided by lower support 504. This supportis preferably constructed or covered with plastic to reduce frictionwith the plastic conveyor belt segments. Lower support 504 is positionedat an incline having a higher end substantially aligned with the lowersurface of a connecting conveyor beam, and having a lower end directedtoward the bottom surface of wheel 508. This configuration acts to guidethe conveyor belt to the wheel 508.

Wheel 508 rotates on axle 510 which is attached to side walls 512 and514. The conveyor belt is drawn around wheel 508 so that the incominglower surface of the conveyor belt is fed out the top of idler end 106.More specifically, after passing around wheel 508, the conveyor beltrests upon upper support 506. Upper support 506 is substantially alignedwith the vertical support blades of the conveyor assembly and with theupper surface of wheel 508. As a result, after the conveyor belt passesaround wheel 508, it remains upon a flat path along the upper surface ofthe conveyor belt.

Turning to FIGS. 6A and 6B, one preferred wheel bend will be described.Wheel bend 108 includes connectors 610 and 612 configured to attach itto a conveyor beams 102. Connectors 610 and 612 are mounted within body614 and extend beyond body 614 to provide an end with approximately thesame shape as one end of connector 116. Accordingly, connectors 610 and612 are used to provide a rigid, high-friction fit with a conveyor beam102.

Support arms 616, 618 and 620 connect to body 614 approximately alongthe path of a circle having a center coincident with the center of axel624. Support arms 616, 618 and 620 have substantially the same shape assupport arm 104 except for pin and bolt assemblies. Support arms 616,618 and 620 are welded directly to body 614, in addition, oralternatively, support arms 616, 618 and 620 may be bolted to body 614.Each support arm 616, 618 and 620 defines a slot 634 that holds a curvedsupport beam 630. Curved support beam 630 follows the path of a circlehaving a center coincident with the center of axel 624. A portion ofcurved support beam 630 is covered by a plastic cap 631. Plastic cap 631extends between the lower surface of the upper portion of the conveyorbelt and the lugs of the plastic segments. Plastic cap supports aportion of the upper surface of belt 112 along the outer side of wheelbend 108 and the inside is supported by upper wheel 626. Upper wheel 626is mounted along axel 624, which is in turn supported by upper axelsupport 622 and body 614. Upper axel support 622 extends from the bodyto the top of axel 624. Upper wheel 626 also includes a lip 627 thatextends between the conveyor surface and lugs of the plastic segments.

In one preferred mode of operation, the conveyor belt moves from the endnearest connector 610 to the end nearest connector 612. The conveyorsegments are received at the end nearest connector 610 and move along acurved path that is also centered coincident with the center of axel624. The lip on plastic cap 631 and the lip 627 on upper wheel 626support the conveyor segments along this path and also prevent thesegments from being lifted off this support surface. Since the conveyorsegments are more likely to jump off of their prescribed path when theyencounter a curve, these lips help prevent such derailments.

The upper face of plastic cap 631 and upper wheel 626 are substantiallyaligned with the vertical support blades of the conveyor assembly. As aresult, the conveyor belt passes smoothly to and from the wheel bend108.

The lower path of belt 112B is supported by a curved face, which is alsocovered by a plastic cap. The curved face is substantially aligned withthe curvature of curved support blade 630. The plastic cap 633 extendsbetween the conveyor surface 112B and lugs of the plastic segments 136B.Accordingly, the plastic cap 633 supports a portion of the lower surfaceof belt 112B along the outer side of wheel bend 108 and the inside issupported by lower wheel 628. Lower wheel 628 is also mounted along axel624, which is in turn supported by upper axel support 622 and body 614.However, since belt 112 moves in the opposite direction along the lowersurface than it does along the upper surface, lower wheel 628 is free torotate in the opposite direction as upper wheel 626. Lower wheel 628also includes a lip 629 that extends between the conveyor surface andlugs of the plastic segments.

As part of conveyor assembly 100, lip 629 will align with plastic cap130A (shown in FIG. 1B), and the other plastic cap will align withplastic cap 130B. With this configuration, the lower portion of belt 112is firmly secured along a continuous path.

Preferably, the connectors 610 and 612, the body 614, the support arms616-618, the curved support beam 630, and the bolt 632 are allconstructed of stainless steel. The upper and lower wheel 626 and 628are preferably constructed of plastic.

Turning to FIG. 7, one preferred end drive 110 will be described. Enddrive 110 includes a body 710 that provides support for the variousdrive components. More specifically, motor 718 connects to body 710. Therotational speed of the motor is decreased through a reducer. Moreover,the drive speed of motor 718 is adjusted in accordance with the needs ofthe associated manufacturing process.

Connector 716 is also attached to body 710 and is configured to attachend drive 110 to a conveyor beam 102. Connector 716 is mounted withinbody 710 and extends beyond body 710 to provide an end withapproximately the same shape as one end of connector 116. Accordingly,connector 716 is used to provide a rigid, high-friction fit with aconveyor beam 102. The opposite faces of body 710 are held together byconnector 716, the axel of gear 722, bolt 724 and coupling nut 725.

Body 710 also connects to an upper support 712, which is substantiallyaligned with support blades 126A and 126B. Gear 722 engages the plasticsections of the belt 112. As gear 722 is driven by motor 718, it drawsbelt 112 toward end drive 110. The belt is passed from support blades126A and 126B to upper support 712. The alignment between blades 126Aand 126B and upper support 712 provides a continuous path for belt 112.

As gear 722 draws plastic segments into drive end 110, the plasticsegments are passed from the upper face to the lower face of theconveyor belt. Lower support 714 receives the plastic segments from thelower side of gear 722 and supports and guides the plastic segments asthey are passed out of end drive 110 to a conveyor beam 102. Lowersupport 714 is positioned at an incline having a higher endsubstantially aligned with the lower surface of a connecting conveyorbeam, and having a lower end directed toward the bottom surface of gear722. This configuration acts to guide the conveyor belt from sprocket722 to conveyor beam 102.

Leg 720 also connects to body 710 and provides support for the end drive110.

Preferably, body 710, upper support 712, lower support 714, connector716 and leg 720 are constructed of stainless steel. Gear 722 and coversfor upper support 712 and lower support 714 (not shown) are preferablyconstructed of plastic.

Turning to FIG. 8, another preferred conveyor beam 802 and connector 804will be described. Connector 804 is preferably constructed fromstainless steel. It includes an upper portion 804A and a lower portion804B. Lower portion 804B includes an upper surface 814 that bends oneach side to form vertical walls 816 and 818. Vertical walls 816 and 818meet the upper surface 814 at approximately a ninety degree angle. Theupper surface 814 defines a plurality of threaded holes configured toreceive bolts 820. Upper portion 804A includes an upper surface 822 thatbends on each side to form side bends 824 and 826.

As bolts 820 are turned through the treaded holes, they push against thelower surface 822. This forces the bottom edge of vertical walls 816 and818 against a lower face 807 of conveyor beam 802. Likewise, this forcesthe upper end of vertical walls 824 and 826 against an upper face 806 ofconveyor beam 802. As bolts 820 are further extended through uppersurface 814, connector 804 forms a rigid, high-friction fit withconveyor beam 802. This prevents any movement between the two parts.Connector 804 is used to make a connection on each of its ends with aconveyor beam so that the two conveyor beams are joined into a singleconveyor beam. Again, this allows easy construction of virtually anylength.

Turning to FIG. 9, another preferred support beam 900 will be described.Support beam 900 is constructed from a sheet of metal having asubstantially rectangular shape. The sheet of metal is bent to form anupper face 910, side walls 912 and 914, and lower face 916. Side walls912 and 914 are also bent to form a convex surface. The bend 913 and 915is used to engage the lower portion of a connector, such as the oneshown in FIG. 8. Support arms may be attached to the support beam 900 inthe same manner as is used to attach support arms to beam shown in FIG.2. In this configuration, the lower profile of the support arms matchthe convex profile of the support beam 900.

Turning to FIG. 10, one preferred guide assembly will be described. Theguide assembly is used to prevent products from falling off of theconveyor assembly, as is especially likely to occur around bends. Guideassembly 1000 includes an accessory bracket 1008, a base 1010, a body1012 and an arm 1014. Accessory bracket 1008 is constructed insubstantially the same manner as arm support 104 except that it does notinclude blade guide 412. Accessory bracket 1008 may be added anywherealong a conveyor beam. Since it does not include an interior blade guide(i.e., blade guide 412), it may be added even after the conveyor hasbeen assembled. Accessory bracket(s) 1008 are added in pairs using atension and compression member as described above with reference to armsupport 104. This configuration forms a rigid friction fit with theconveyor beam 102.

Base 1010 includes a vertical mounting surface 1016 and a horizontalsupport surface 1018. Mounting surface 1016 defines a hole. Mountingsurface 1016 is placed against accessory bracket 1008 and its hole isaligned to pass a bolt 1011 through to accessory bracket 1008. Bolt 1011engages a coupling nut and forms part of the tension member, which isfurther described above.

The lower exterior face of accessory bracket 1008 defines asubstantially horizontal groove 1009. The lower end of mounting surface1016 has a protruding lip to engage the horizontal groove 1009. Thissecures the base 1010 in a perpendicular position while using only onebolt to attach the base. Moreover, this attachment mechanism does notrequire any further drilling or any other manufacturing process.

Support surface 1018 also defines a hole (or multiple holes) along itsouter end. This hole passes bolt 1020, which connects with a lower endof body 1012. Body 1012, also defines a passage for arm 1014 andincludes a threaded knob 1022 that is used to hold arm 1014 in place.Loosening knob 1022 allows arm 1014 to slide through the passage in body1012 in a horizontal direction. Arm 1014 connects to a guide 1024 (shownin cross section) that runs along the length of the conveyor. Arm 1014is adjusted in accordance with the width of the products carried by theconveyor. Preferably, base 1010, body 1012 and arm 1014 are constructedof stainless steel. Preferably, a guide assembly is provided along bothsides of the conveyor belt. This keeps products within a prescribed pathalong the conveyor

Turning to FIG. 11, another preferred guide assembly will be described.Guide assembly 1100 includes a base 1110 that connects to a body 1112and connects to an arm 1114. Base 1110 defines a hollow shaft that isconfigured to pass a bolt. This allows for convenient connection to asupport arm 104 or to an accessory bracket 1008. That is, the bolt 124,which is used in a support arm assembly, may be passed through base 1110and secured to the support arm; or the bolt 1011, which is shown in FIG.10, may be passed through base 1110 and secured to the accessorybracket.

Base 1110 is aligned along a substantially horizontal plane and alsodefines a vertical passage through which body 1112 passes. This verticalpassage extends through a bolt 1122 having a ring or hoop head. Bolt1122 is further described below with reference to FIG. 12. Knob 1120includes a threaded engagement with bolt 1122. As knob 1120 is tightenedagainst base 1110, it draws an interior surface of bolt 1122 againstbody 1112 to secure it in place. Knob 1120 may also be loosened toreadjust the vertical position of body 1112. This height is adjusted inaccordance with the product(s) that will be carried along the conveyorassembly.

The top of body 1112 also includes a threaded knob 1118 that is used tosecure arm 1114. Knob 1118 may be loosened to allow horizontaladjustment of arm 1114. Arm 1114 connects with guide 1116, which runsalong the length of the conveyor.

Preferably, base 1110, body 1112 and arm 1114 are constructed ofstainless steel. Preferably, a guide assembly is provided along bothsides of the conveyor belt. This keeps products within a prescribed pathalong the conveyor.

Turning to FIG. 12, bolt 1122 includes a ring head 1212 and a threadedbody 1210. Body 1122 passes through ring head 1212, and knob 1120engages the threaded body. Again, as the knob is tightened against base1110, the ring head 1212 presses body 1112 (or arm 1114) against base1110 (or bracket 1124) to form a rigid friction fit.

Turning to FIGS. 13A and 13B, one preferred leg attachment mechanism1300 will be described in further detail. The attachment mechanism 1300includes a leg 1310, a base 1312, a pair of side arms 1314, and a pairof leg brackets 1316. Base 1312 connects to leg 1310 using a mechanismthat is commonly used to attach the handlebars of a bicycle to the frontwheel forks. Specifically, base 1312 defines a hole through which thebody of a bolt 1318 is passed. The bolt 1318 passes through a hollowcylinder 1320. The hollow cylinder 1320 has an inclined lower face. Bolt1318 engages a threaded cylinder 1322. The threaded cylinder 1322 has aninclined upper face that presses against the inclined lower face ofhollow cylinder 1320. As bolt 1318 is tightened against base 1312, itdraws threaded cylinder 1322 against hollow cylinder 1320. The inclinedfaces, in turn, force the cylinders 1320 and 1322 to move in opposingdirections against an interior surface of leg 1310. This operates toform a rigid friction fit between base 1312 and leg 1310.

Each side arm 1314 attaches to base 1312 using a pair of bolts 1324.Side arm 1314 defines a lower hole 1326 and an upper hole 1328.Likewise, base 1312 defines a lower hole that aligns with lower hole1326. Base 1312 also defines a slot 1330 that follows an arch centeredabout the lower hole. A bolt 1324 is passed through the lower holes inthe side arm 1314 and base 1312. Another bolt is passed through theupper hole in side arm 1314 and the slot 1330. This configuration allowsside arm to be adjusted to various angles. For example, when used inconjunction with an inclined conveyor belt, the side arms would betilted so that they meet the associated conveyor beam at anapproximately right angle.

The upper portion of side arm 1314 defines a pair of holes 1332. Theseholes align with holes in leg bracket 1316. Leg bracket 1316 isconstructed in a manner similar to that of support arms 104, except thatthey do not include blade guides 410 and 412 nor compression pins 120.In other words, leg bracket is constructed so that its lower portionsubstantially matches the profile of a conveyor beam. Bolts 1334 arepassed through the holes in side arm 1314 and leg bracket 1316. Bolts1334, in turn, engage coupling nut 1336. As the bolts 1334 aretightened, leg brackets 1316 are drawn against the sides of conveyorbeam 1338. This forms a rigid friction fit between the conveyor beam1338 and leg 1310.

In many applications, a manufacturing process will require a primaryassembly line and a second line that is used to divert products. Inthese circumstances, a second conveyor belt may be operated adjacent toand parallel with the primary conveyor belt. A simple gate is used todivert products from the primary conveyor belt to the second conveyorbelt. The primary and secondary conveyor belts may be attached to eachother so that they remain a fixed distance apart.

Turning to FIG. 14, one preferred conveyor beam attachment bracket 1400will be described. The attachment bracket 1400 is used to connect twoconveyor beams in parallel. The attachment bracket 1400 includes a plate1410, a bolt 1412 and a separation rod 1414. Plate 1410 spans across twoconveyor beams 1416 and 1418. The outer portion of plate 1410 curvesaround conveyor beams 1416 and 1418, to engage their exterior walls. Rod1414 is aligned substantially parallel with conveyor beams 1416 and1418. Rod 1414 also defines a threaded hole. Bolt 1412 passes through ahole that is centered in plate 1410 to engage the threaded hole in rod1414. As bolt 1412 is tightened against plate 1410, it draws rod 1414against the interior walls of conveyor beams 1416 and 1418. This, inturn, presses the exterior walls of conveyor beams 1416 and 1418 againstthe outer portions of plate 1410. As the bolt 1412 is further tightened,the conveyor beams form a rigid friction fit with attachment bracket1400. Two or more such attachment brackets may be used along a pair ofconveyor beams to maintain a fixed parallel pathway as between the pairof conveyor beams.

Turning to FIGS. 15A-15C, one preferred attachment block 1500 will bedescribed. FIG. 15A shows a plan view of attachment block 1500 havingsides 1510 and 1520. FIG. 15B shows an elevation view of side 1510 aswell as support blade 126 and accessory 1512 (cut away view), and bolt1514. FIG. 15C shows an elevation view of side 1520.

Attachment block 1500 defines a slot 1502 and hole 1504. Slot 1502 isconfigured to engage support blade 126. Attachment block 1500 furtherdefines two threaded holes 1506 and 1508 that meet slot 1502. Slot 1502is positioned under support blade 126 so that support blade 126substantially fills slot 1502. Bolts 1516 are turned through threadedholes 1506 and 1508. The end of bolts 1516 press against blade 126 toform a rigid friction fit.

Hole 1504 is configured to receive the support arm of an accessory 1512.Attachment block further defines a threaded hole 1510 that meets hole1504. Accessory 1512 passes through hole 1504. A bolt 1514 is thenturned through threaded hole 1510. The end of bolt 1514 presses againstaccessory 1512 to form a rigid friction fit.

Turning to FIG. 16A-C another preferred connector 1600, which is used toconnect two beams, will be described. The connector 1600 includes a body1606, which is preferably constructed from a single sheet of bentstainless steel. The body 1606 has a flat top 1608, which extends fromend 1602 to end 1603. The body bends on each side of flat top 1608 tojoin an inclined left side 1620 and an inclined right side 1622. Theseare bent so that each inclined side meets the flat top 1608 to form anobtuse interior angle. Both the inclined left side 1620 and the inclinedright side 1622 also extend from end 1602 to end 1603. The body alsobends along the inclined sides to from a vertical left side portion 1624and a vertical right side portion 1626. The angle between the verticalleft side portion 1624 and the inclined left side 1620 forms an obtuseinterior angle and the angle between the vertical right side portion1626 and the inclined right side 1622 also forms an obtuse interiorangle. The vertical sides also extend from end 1602 to end 1603. Thevertical sides end in bottom edges 1640. Preferably, the body 1606 issymmetric so that the right and left sides are mirror images of oneanother.

Left friction rod 1610 is placed along the upper left side of body 1606and right friction rod 1612 is placed along the upper right side of body1606. Preferably, the friction rods extend from end 1602 to end 1603.The friction rods connect to body 1606 by bolts spaced along the lengthof body 1606. The bolts nearest end 1602 are shown in FIG. 16B as bolts1630 and 1632. With reference to left friction rod 1610, bolt 1630passes through a threaded hole in inclined left side 1620. The end ofbolt 1630 fits within a round hole in the side of left friction rod1610. As the bolt 1630 is turned or tightened, the end of bolt 1630pushes left friction rod 1610 outward away from body 1606. The bolt 1632and right friction rod 1612 operates in the same manner. The leftfriction rod 1610 lies parallel to the bends along the inclined leftside 1620 and the right friction rod lies parallel to the bends alongthe inclined right side 1622. Proximate each of the bolt connectionsalong the left and right friction rods, the outer surface of the rods isroughened. When the connector 1600 is used to form a friction fit with abeam, the roughened surface increases the friction between the twopieces.

Turning to FIG. 17, connector 1600 is shown inside the end of a beam. Asbolts 1630 and 1632 are tightened, friction rods 1610 and 1612 pushagainst the upper interior corners of beam 1702. Likewise, the bottomedges 1640 press against the interior bottom of beam 1702. As the boltsalong the friction rods are all tightened, the connector 1600 forms asolid, friction fit with the beam 1702.

Although the invention has been described with reference to specificpreferred embodiments, those skilled in the art will appreciate thatmany variations and modifications may be made without departing from thescope of the invention. Likewise, where certain components have beendescribed using particular materials or construction techniques, thoseskilled in the art will appreciate that other materials and/orconstruction techniques may be used without departing from the scope ofthe invention. The following claims are intended to cover all suchvariations and modifications.

1. A conveyor belt system comprising: a first beam defining a firstinterior channel; a second beam defining a second interior channel; aconnector comprising an adjustable element for making a friction fitbetween the first interior channel and the second interior channel; anda track running above the first and the second beam and wherein thetrack connects with the first beam and the second beam by a plurality ofvertical arms spaced along and forming a friction fit with the firstbeam and the second beam.
 2. The conveyor belt system of claim 1,further comprising a plurality of interlocking plastic segments.
 3. Aconveyor belt system comprising: a first beam defining a first interiorchannel; a second beam defining a second interior channel; a connectorfor making a friction fit between the first interior channel and thesecond interior channel; and a track running above the first and thesecond beam and wherein the track connects with the first beam and thesecond beam by a plurality of vertical arms spaced along and forming afriction fit with the first beam and the second beam.